Environmentally friendly apparatus and method for surface printing

ABSTRACT

An apparatus and method for applying an informational patter to a surface is provided. The apparatus includes a system configured to apply fluid on a surface to form the informational pattern, a surface preparation unit for preparing the surface, and a spray head system for applying the informational pattern.

PRIORITY

The present disclosure claims priority to and benefit of U.S.Provisional Patent Application No. 61/258,069, filed Nov. 4, 2009, andtitled “APPARATUS AND METHOD FOR SURFACE PRINTING,” which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present disclosure is generally directed to an apparatus and methodfor applying a fluid to a surface. More particularly, the presentdisclosure is directed to an apparatus and method for applying aninformation pattern to a surface.

BACKGROUND OF THE INVENTION

Surfaces, such as pavement, commonly include an information pattern toconvey information. Information patterns may be in the form of symbolsand/or words. For example, information patterns may include arrows orletters, such as “stop”.

The most common approach to marking a pavement surface is to apply astencil and to use a paint gun or brush to apply paint to thepattern-defining apertures in the stencil. However, these priorapproaches have numerous problems, including, but not limited toprotecting workers as the information pattern is applied. Often theseprocesses involve high-solvent paints so that they cure quickly. Thehigh-solvent paints can include dangerous fumes and environmentallyunfriendly materials.

Decals can be applied to surfaces to convey information as well.However, the decals can be expensive to manufacture and/or may involvesubstantial effort by individuals placing the decals. In addition, thedecals can deteriorate requiring a completely new decal to be necessary.

An apparatus and method capable of applying a fluid to a surface inquickly, effectively, and/or in an environmentally-friendly manner wouldbe desired in the art.

BRIEF DESCRIPTION OF THE INVENTION

In an exemplary embodiment, a fluid application apparatus includes asystem configured to apply fluid on a surface to form an informationalpattern, a surface preparation unit for preparing the surface, and aspray head system for applying the informational pattern.

In another exemplary embodiment, a fluid application apparatus includesa fluid application system configured to apply fluid on a surface toform an informational pattern, a spray head system, a spray head systemactuator, and a surface preparation unit. The spray head system actuatoradjusts the fluid application apparatus between a transportconfiguration and an application configuration.

In another exemplary embodiment, a method of applying fluid on a surfaceproviding a fluid application apparatus and applying fluid on thesurface to form an information pattern. The fluid application apparatusincludes a fluid application system configured to apply fluid on asurface to form the informational pattern and one or more of a positionindication device and a spray head system actuator. The positionindication device gathers data relating to a global position of thefluid application apparatus or a relative position of at least a portionof the fluid application system compared to the surface. The spray headsystem actuator adjusts the fluid application apparatus between atransport configuration and an application configuration.

One advantage of an exemplary embodiment of the invention includes theability to apply a fluid to a surface in an informational pattern havingresolution capable of being understood by individuals standing close tothe informational pattern.

Another advantage of an exemplary embodiment of the invention includeshaving adhesion to the surface permitting an informational pattern toremain on the surface during use of the surface.

Another advantage of an exemplary embodiment of the invention includesbeing capable of conveying information about a product or sponsorthrough an informational pattern on a surface.

Another advantage of an exemplary embodiment of the invention includesfostering safety for individuals applying a fluid to a surface andindividuals proximal to the application of the fluid to the surface.

Another advantage of an exemplary embodiment of the invention includesbeing environmentally friendly in comparison to other methods ofapplying fluids to surfaces.

Other features and advantages of the present disclosure will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view an exemplary an apparatusaccording to an embodiment of the disclosure.

FIG. 2 illustrates reverse perspective view of the exemplary apparatusillustrated in FIG. 1.

FIG. 3 shows a side view of an exemplary apparatus positioned in atransport configuration according to an exemplary embodiment of thedisclosure.

FIG. 4 shows a side view of an exemplary apparatus positioned in anapplication configuration according to an exemplary embodiment of thedisclosure.

FIG. 5 shows a portion of an exemplary spray head system according to anexemplary embodiment of the disclosure.

FIG. 6 shows a portion of an exemplary spray head system according to anexemplary embodiment of the disclosure.

FIG. 7 shows a bottom view of a portion of an exemplary surfacepreparation unit according to an exemplary embodiment of the disclosure.

Wherever possible, the same reference numbers will be used throughoutthe drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is an apparatus and method for applying a fluid to a surface toform an informational pattern. Embodiments of the apparatus and methodpermit application of a fluid to any surface suitable for receiving theapplied fluid (for example, a road surface), permit application of thefluid in a controlled pattern to form the information pattern (forexample, symbols and/or words such as company logos, trademarks,symbols, and lettering), permit application without requiring anoperator to be positioned on the printing surface, permit adhesion for alack of adhesion) to be adjusted, and/or are environmentally friendly incomparison to other methods of applying fluids to surfaces.

FIGS. 1-2 show an exemplary embodiment of a fluid application apparatus100. The fluid application apparatus 100 includes a fluid applicationsystem 120 configured to apply fluid on a surface 501 as shown in FIGS.3-4 to form an informational pattern. The fluid application apparatus100 includes one or more of a position indication device and a sprayhead system actuator 510. The position indication device gathers datarelating to a longitudinal position of the fluid application apparatus100 or a relative position of at least a portion of the fluidapplication system 120 compared to the surface 501. The spray headsystem actuator 510 adjusts the fluid application apparatus 100 betweena transport configuration and an application configuration.

The surface 501 may be a suitable surface for receiving the appliedfluid. In one embodiment, the surface 501 may be a manufactured surface,such as, but not limited to an asphalt, concrete, artificial turf, orother suitable surface. In another embodiment, the surface 501 may be anatural surface such as a grass surface or field surface. The fluid isany suitable fluid. For example, the fluid may be selected from a groupincluding, but not limited to, a marking fluid, a cleaning, fluid, achemical solution, a poison, and a fertilizer solution. In oneembodiment, the marking fluid may be a paint, dye, ink or other suitablemarking liquid. The marking fluid may be a permanent or temporarymarking liquid. The fluid may be a liquid, a liquid with dissolvedsolids, a liquid with dispersed and/or suspended solids, a pressurizedgas that sublimes upon contact with the surface 501, or any othersuitable fluid capable of being applied to the surface 501.

Referring again to FIGS. 1-2, the apparatus 100 includes a frame 110.The frame 110 provides mobility and support permitting the fluidapplication apparatus 100 to be used in the transport configuration andthe application configuration. The frame 110 is formed of any suitablematerial. For example, the frame 110 can be metal, composite, polymeric,or any other suitable material capable of supporting the fluidapplication system 120. The frame 110 supports any suitable combinationof a rear bumper 146, a surface preparation unit 140, wheels 210, acleaning tray 105, a spray head system 114, any combination thereof, orany other suitable portion of the apparatus 100.

For supporting the components of the apparatus 100, the frame 110includes a main frame section 142 (for example, supporting the surfacepreparation unit 140) and a spray head frame section 144 (for example,supporting the rear bumper 146). In one embodiment, a housing (notshown) extends from the frame 110 at least partially enclosing the fluidapplication system 120. In another embodiment, the housing is omitted.In one embodiment, the apparatus 100 is moved by rotation of the wheels210 by an external force such as a vehicle towing the apparatus 100 (forexample, a truck, car, tractor, or other self-propelled vehicle). In analternate embodiment, the frame 110 is configured for being positionedin a vehicle (not shown) such as in the bed of a truck. Stated anotherway, in the alternate embodiment, the frame 110 permits the apparatus100 to be positioned on a pallet or palletized. In this embodiment, thepositioning of components within the apparatus 100 may be rearranged ormodified for additional protection and/or additional efficacy. Forexample, the surface preparation system 140 may be provided as aseparate unit installed in front of the spray head system 114, forexample, in front of the support vehicle.

In one embodiment, prior to applying the fluid to the surface 501, thesurface is prepared by the surface preparation system 140. The surfacepreparation may include cleaning the surface 501, treating the surface501, smoothening the surface 501, roughening the surface 501, sealingthe surface 501, any combination thereof, or other suitable preparationsteps. In one embodiment, the apparatus 100 includes additional surfacepreparation devices, such as brushes that may be directional and/orrotational, for removing debris from the surface 501.

Referring to FIGS. 3-4, in one embodiment, the surface preparationsystem 140 includes an air dryer 641. The air dryer 641 is in fluidcommunication to receive pressurized air from a pneumatic system 111(for example, by a pressurized air distribution system controlling therelease of pressurized air to the air dryer 641). The air dryer 641distributes and directs the pressurized air towards the surface 501. Theair dryer 641 includes a dryer body 642 and casters 643. The dryer body642 can he raised and lowered by linkages, supports and actuatorsoperating in conjunction with the castors. Additionally oralternatively, the surface preparation unit 140 may include additionalgaskets and/or other fluid directing devices to generally direct thepressurized air towards the surface 501.

FIG. 7 shows a bottom view of a portion of the air dryer 641 accordingto an embodiment. In this embodiment, the air dryer 641 includes dryerbody 642, an air knife 644, and a gasket 646. The air knife 644 includesa plurality of apertures or air nozzles 648 for directing pressurizedair towards the surface 501. The pressurized air may dry the surface 501and/or remove debris from the surface 501. The gasket 646 assists indirecting fluid from the surface away from the spray area. In oneembodiment, there is a gap between the air knife 644 and the floor ofthe dryer body 642. This gap exposes the surface 501 to the highvelocity air. There is a lip on the floor of the dryer body 642. Thislip creates a channel through which water is collected during thisprocess (for example, water removed from the surface 501). One end ofthe dryer body 642 is closed, the other open. Water flows in the channeland out the open end of the dryer body 642. The dryer body 642 is set ata predetermined angle substantially perpendicular to the movement of theair dryer 641.

Referring again to FIGS. 3-4, in embodiments having the surface 501prepared by the surface preparation system 140, the fluid is applied bythe fluid application system 120 thereafter. For example, the apparatus100 may move along a road substantially continuously preparing the roadwith the surface preparation system 140 and substantially continuouslyapplying the fluid with the fluid application system 120 after the roadis prepared. In embodiments without the surface 501 being prepared, thefluid is applied by the fluid application system 120 at any suitabletime.

The fluid application system 120 includes any suitable components.Referring to FIGS. 1-2, in one embodiment, the fluid application system120 of the apparatus 100 includes a power unit 101, a fluid supply 104,a fluid pumping system 106, a control system 108, a pneumatic system111, and a spray head system 114. The power unit 101 includes aninternal combustion engine 202, an oil pump 203, an oil reservoir 204,an oil accumulator 205 (see FIG. 2), a dump valve 206 (see FIG. 2), anda fuel supply 207 (see FIG. 2). The apparatus 100 includes an electricalpower system (not shown). The electrical power system may be a gas ordiesel driven generator or a generator powered by the power unit 101.

The fluid supply 104 includes one or more fluid supplies, for example, amarking fluid supply 212 and a cleaning fluid supply 222 (see FIG. 2).The marking fluid supply 212 includes one or more supply containers, forexample, a first marking fluid supply container 212 a and a secondmarking fluid supply container 212 b. The cleaning fluid supply 222includes one or more supply containers, for example, a first cleaningfluid supply container 222 a and a second cleaning fluid supplycontainer 222 h. In one embodiment, the marking fluid containers 212 a,212 b and the cleaning fluid containers 222 a, 222 b are reusable and/orresealable. For example, the containers 212 a, 212 b, 222 a, 222 b mayinclude openings that are opened and/or closed upon attachment to theapparatus 100.

Fluid is pumped from the fluid supply 104 by the fluid pumping system106. The fluid pumping system 106 may include one or more pumps. Forexample, in one embodiment, the pumping system 106 includes a pump 106a. The pumping system 106 includes a fluid distribution system includingany suitable fluid distribution components such as, but not limited topiping, valves, and manifolds for providing fluid to the spray headsystem 114 from the fluid supply 104.

The spray head system 114 includes any suitable spray applicationdevice. For example, in one embodiment, the spray head system 114includes a print head. The spray head system 114 includes banks ofmultiple automatic airless spray guns arranged in a substantially lineararray. Each automatic spray gun is actuated via the pneumatic system 111(having one or more pneumatic and/or hydraulic cylinders an electricsolenoid. The pneumatic system 111 includes an air accumulator and anair compressor and an air valve system. The pneumatic and/or hydrauliccylinders are pressurized by solenoid driven valves. FIG. 5 shows anexemplary embodiment a portion of the spray head system 114 (see regionA of FIG. 4). In this embodiment, the spray head system 114 includes anozzle manifold 710, a nozzle plate 720, a nozzle plate clamp 730, anozzle plate catch plate 740, and a solenoid connector 750. FIG. 6 showsanother exemplary embodiment a portion of the spray head system 114, Inthis embodiment, the components the spray head system 114 are enclosedby a spray head system housing 814.

Referring again to FIGS. 1-2, in one embodiment, the spray head system111 is positioned on a spray head system position assembly 122. Thespray head system position assembly 122 includes a plurality of barlinkages and an actuator 510 configured to raise and lower the sprayhead system 114. The actuator 510 may be a motor, hydraulic device,pneumatic device or other positioning component that can be actuated tolower and raise the spray head system 114 to and from the applicationconfiguration. In another embodiment, the spray head system positionassembly 112 may include an electrical, pneumatic, or other device tolower and raise the print head. system 114. In yet another embodiment,the spray head system position assembly 112 may be manually lowered andraised.

The spray head system 114 and the surface preparation system areconfigured to be lowered to a position proximate a surface 501. Thespray head system 114 is lowered by actuating the actuator 510 andmoving the first, second and third bar linkages 502, 503, 504 (see FIGS.3-4) to a lowered position. The surface preparation system 140 islowered to a position proximate the surface 501.

Referring again to FIG. 6, in one embodiment, the spray head system 114includes a plurality of print head nozzles 810 and a plurality ofpressure wash nozzles 820. The pressure wash nozzles 820 (and valves)are in fluid communication with the same fluid supply 104 as theprinting valves. To clean the surface 501, and in particular to cleanthe surface 501 of markings or information patterns applied by the sprayhead system 114, the fluid application system 120 is pressurized with acleaning solution (for example, a solvent or an environmentally friendlysolution having an abrasive composition) contained in the cleaning fluidsupply 222. The cleaning solution is sprayed onto the surface 501through the pressure wash nozzles 820. In one embodiment, the pressurewash nozzles are only actuated when the supply line is pressurized withclean water or cleaning fluid to flush the fluid application system 120.

During cleaning, the cleaning tray 105 slides under the spray headsystem 114. In one embodiment, the cleaning tray 105 is only able to heused during the transport configuration when the spray head system 114is retracted or stored within the frame 110. In a method of cleaning thespray head system 114, marking fluid is purged from the supply lines andvalves by directing a cleaning fluid contained in a spray head cleaningfluid supply (not shown) through the spray head system 114. The usedcleaning fluid is collected, by the cleaning tray 105 by a suitablefluid collection system (not shown). For example, a suction hoseconnected to a disposal tank.

Referring to FIGS. 3-4, the apparatus 100 further includes a positionindication device 170. The position indication device 170 includes anencoder caster wheel 172 and an encoder 174. The position indicationdevice 170 provides position data to the control system 108. Theposition data may include, but is not limited to, the distance of travelof the apparatus 100 and speed of travel of the apparatus 100. Theapparatus 100 further includes a caster wheel 176 to assist in providinguniform contact with the surface 501 (see FIG. 6).

Referring to FIG. 6, in one embodiment, as the apparatus 100 moves, theencoder caster wheel 172 informs the control system 108 of the relativeposition of the spray head system 114 to the surface 501, if the surface501 is wet, the surface preparation unit 140, including the air dryer641, is deployed and activated. In one embodiment, air is only suppliedto the air dryer 641 while the air dryer 641 moves over the areas of thesurface 501 to be printed on. A dump valve is automatically actuated,which pressures the hydraulic system, which in turn pressurizes thefluid system via the pumping system 106. As the apparatus 100 continuesto move, the control system 108 actuates the pneumatic system 111 in acomputed pattern. Each valve (not shown) is tied to a spray gun in thespray head system 114. As each spray gun is pneumatically pressurized, apneumatic cylinder in the gun opens a zero-flow valve, which releasespressurized fluid to be applied to the surface 105. By turning thenozzles 810 on and off in a computed pattern while the apparatus 100 ismoving, text or images are applied on the ground.

In the application configuration, the encoder caster wheel 172 is incontact with the surface 501 to provide position data to the controlsystem 108. The encoder wheel 172 and castor wheel 811 assist inmaintaining the spray head system 114 at a substantially constant fixeddistance from the surface 501. Similarly, the caster wheels 643maintaining the air dryer 641 at a substantially constant fixed distancefrom the surface 501.

Referring to FIGS. 3-4, in an exemplary method of operating theapparatus 100, the apparatus 100 is converted between the transportconfiguration and the application configuration by lowering/deploying orraising/retracting the spray head system 114 and/or the surfacepreparation unit 140. A data input is provided to the control system108. In one embodiment, the spray head system 114 and the surfacepreparation unit 140 may be lowered in response to a command in the datainput. In one embodiment, an outside computer supplies a message for thesystem to print, or a command is input directly into the microprocessor.As will be appreciated by those skilled in the art, any suitable aspectof operation of the apparatus 100 may be adjusted and/or maintained bythe control system 108. For example, in one embodiment, the containers212 a, 212 b, 222 a, 222 b include microcontrollers and/or sensors thatrecord and/or sense the amount of fluid per container. Themicrocontrollers provide data to the control system 108. In yet anotherembodiment, the microcontrollers include pump data obtained from thecontrol system 108 as to the amount of fluid pumped per container.

In one embodiment, the control system 108 includes a machine controlinterface that communicates with the microprocessor and various encodersthat drive the various components of the fluid application system 120,including the power unit 101, the fluid supply 104, the pumping system106, the pneumatic system 111, and the spray head system 114. Forexample, the control system 108 provides control inputs to the valvedrive electronics to control hydraulic and pneumatic valves in the powersystem (not shown) and pneumatic system 111, respectively. The controlsystem 108 includes data or accepts data as to the information patternapplied or sprayed by the spray head system 114. The control system 108includes command functions for controlling the operation of the sprayhead system 114 to spray or print the information pattern.

In one embodiment, the control system 108 includes control components(not shown), including, but not limited to a microprocessor, valve driveelectronics and a power supply. In one embodiment, the microprocessor isa computer, central processing unit (CPU), or electronic circuit boardcapable of executing command functions. The computer may be a portablecomputer, such as, but not limited to a laptop computer. Themicroprocessor may include input devices, such as such as, but notlimited to USB ports, ethernet ports, and disk drives. In anotherembodiment, the input device may include a wireless system for receivingdata input for the control system 108. The microprocessor may alsoinclude a keyboard or other manual data entry device to manually receivea data input or commands. The microprocessor may further include amonitor for monitoring the input data and/or operational data of theapparatus 100. The power supply may be a battery. The microprocessor mayinclude a memory module. The memory module may include an internaland/or external memory module. For example, the memory module may beRAM, ROM or other memory for receiving and storing coded programs forexecuting the method of the present disclosure.

While the disclosure has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated. for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

1. A fluid application apparatus (100), comprising: a system (120)configured to apply fluid on a surface (501) to form an informationalpattern; a surface preparation unit (140) for preparing the surface(501); and a spray head system (114) for applying the informationalpattern.
 2. The apparatus (100) of claim 1, further comprising a sprayhead system actuator (510).
 3. The apparatus (100) of claim 2, whereinthe spray head system actuator (510) is configured to adjust the fluidapplication apparatus (100) between a transport configuration and anapplication configuration.
 4. The apparatus (100) of claim 3, furthercomprising a cleaning tray (105) configured to be slid under the sprayhead system (114) in the transport configuration.
 5. The apparatus 00)of claim 1, further comprising a position indication device.
 6. Theapparatus (100) of claim 2, wherein the position indication devicegathers data relating to a longitudinal position of the fluidapplication apparatus (100).
 7. The apparatus (100) of claim 2, whereinthe position indication device gathers data relating to a relativeposition of at least a portion of the fluid application system (120)compared to the surface (501).
 8. The apparatus (100) of claim 7,wherein the surface preparation unit (140) is configured for therelative position in comparison to the surface (501) to be adjusted inresponse to the data gathered by the position indication device.
 9. Theapparatus (100) of claim 7, wherein the spray head system (114) isconfigured for the relative position in comparison to the surface (501)to be adjusted in response to the data gathered by the positionindication device.
 10. The apparatus (100) of claim 1, wherein thesurface preparation unit (140) comprises an air dryer (641) positionedto direct air onto the surface (501).
 11. The apparatus (100) of claim10, wherein the surface preparation unit (140) is configured to smoothenthe surface
 501. 12. The apparatus (100) of claim 10, wherein thesurface preparation unit (140) is configured to roughen the surface 501.13. The apparatus (100) of claim 10, wherein the surface preparationunit (140) is configured to remove debris from the surface
 501. 14. Theapparatus (100) of claim 10, wherein the surface preparation unit (140)further comprises brushes.
 15. The apparatus (100) of claim 1, furthercomprising: a spray head system actuator (510), the spray head systemactuator (510) configured to adjust the fluid application apparatus(100) between a transport configuration and an applicationconfiguration; a position indication device configured to gather datarelating to a longitudinal position of the fluid application apparatus(100) or a relative position of at least a portion of the fluidapplication system (120) compared to the surface (501); and an air dryer(641) positioned to direct air onto the surface (501).
 16. A fluidapplication apparatus (100), comprising: a fluid application system(120) configured to apply fluid on a surface (501) to form aninformational pattern; a spray head system (114); a spray head systemactuator (510); a surface preparation unit (140); wherein the spray headsystem actuator (510) adjusts the fluid application apparatus (100)between a transport configuration and an application configuration. 17.The apparatus (100) of claim 16, further comprising a positionindication device configured to gather data relating to a longitudinalposition of the fluid application apparatus (100) or a relative positionof at least a portion of the fluid application system (120) compared tothe surface (501).
 18. A method of applying fluid on a surface, themethod comprising: providing a fluid application apparatus, the fluidapplication apparatus (100) comprising: a fluid application system (120)configured to apply fluid on a surface (501) to form an informationalpattern; and one or more of a position indication device and a sprayhead system actuator (510); wherein the position indication devicegathers data relating to a global position of the fluid applicationapparatus (100) or a relative position of at least a portion of thefluid application system (120) compared to the surface; wherein thespray head system actuator (510) adjusts the fluid application apparatus(100) between a transport configuration and an applicationconfiguration; and applying fluid on the surface (501) to form theinformation pattern.
 19. The method of claim 18, further comprisingpreparing the surface prior to applying the fluid.
 20. The method ofclaim 18, further comprising adjusting the relative distance the atleast portion of the fluid application system (120) in response to thedata gathered, wherein the position indication device gathers datarelating to the relative position of the at least portion of the fluidapplication system (120) compared to the surface (501).